• 제어로봇시스템학회:학술대회논문집
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• 제어로봇시스템학회 1987년도 한국자동제어학술회의논문집; 한국과학기술대학, 충남; 16-17 Oct. 1987
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• pp.232-236
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• 1987

To improve the surface waviness in the peripheral milling, since the tool deflection is largely affected by cutting force, the feedrate is controlled so that the cutting force measured in the normal direction to the workpiece is constant. A discrete time first order model between the feedrate and the tool deflection is derived for the control. The experimental results show that the surface waviness is greatly improved by the proposed method.

• Coupled systems mechanics
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• 제4권4호
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• pp.279-295
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• 2015

The article presents a theoretical-experimental approach developed for modeling the coefficient of sliding friction in the dynamic system tool-workpiece in slide diamond burnishing of low-alloy unhardened steels. The experimental setup, implemented on conventional lathe, includes a specially designed device, with a straight cantilever beam as body. The beam is simultaneously loaded by bending (from transverse slide friction force) and compression (from longitudinal burnishing force), which is a reason for geometrical nonlinearity. A method, based on the idea of separation of the variables (time and metric) before establishing the differential equation of motion, has been applied for dynamic modeling of the beam elastic curve. Between the longitudinal (burnishing force) and transverse (slide friction force) forces exists a correlation defined by Coulomb's law of sliding friction. On this basis, an analytical relationship between the beam deflection and the sought friction coefficient has been obtained. In order to measure the deflection of the beam, strain gauges connected in a "full bridge" type of circuit are used. A flexible adhesive is selected, which provides an opportunity for dynamic measurements through the constructed measuring system. The signal is proportional to the beam deflection and is fed to the analog input of USB DAQ board, from where the signal enters in a purposely created virtual instrument which is developed by means of Labview. The basic characteristic of the virtual instrument is the ability to record and visualize in a real time the measured deflection. The signal sampling frequency is chosen in accordance with Nyquist-Shannon sampling theorem. In order to obtain a regression model of the friction coefficient with the participation of the diamond burnishing process parameters, an experimental design with 55 experimental points is synthesized. A regression analysis and analysis of variance have been carried out. The influence of the factors on the friction coefficient is established using sections of the hyper-surface of the friction coefficient model with the hyper-planes.

• 한국공작기계학회논문집
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• 제10권3호
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• pp.68-74
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• 2001

In the drawing of large size automotive panels, elastic deflection of die components is induced by the contact force between them. The deflection is nonuniform and locally distributed, and results in nonuniform material flow. In order to arrange such a nonuniform die gap, a correcting operation, so called die spotting, is inevitable, which requires trial and error works and consuming time. A prediction of the bending deflection prior to a try-out must be useful to reduce the die spotting time. In this study, drawing process of a front fender is simulated first. and the deflection of the blank holder is calculated from the contact force imposing on th blank holder. The balance block heights ensuring a uniform deflection are optimized by the analysis and design of experiments.

• 소성∙가공
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• 제22권6호
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• pp.310-316
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• 2013

Recently, numerical predictions of surface deflection based on curvature analysis have been developed. In the current study, a measure of surface deflection is proposed as the maximum variation of curvature difference between the panel and the tool in order to account for surfaces that have high curvature. The current study focused on the assessment of accuracy for the surface deflection prediction with the consideration of planar anisotropy. As an example, a shallow rectangular drawn part with rectangular embossing was considered. In terms of the proposed surface deflection measure, the maximum variation of curvature difference, the prediction with a planar anisotropic model shows better correspondence with experiment than the one using a normal anisotropic model.

• 한국정밀공학회:학술대회논문집
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• 한국정밀공학회 1995년도 추계학술대회 논문집
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• pp.961-964
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• 1995

For geometric accuracy in the net shape machining, the problem of tool deflection should be resolved in some fashion. In particular, this is crucial in finish cut operation where slim tools are used. The purpose of this paper is to verify the validity and effectiveness of the prediction model of the machined surface. Experimental results are presented for the cut of steel material with HSS endmill of diameter 6mm on machining center. The results shows that 1) the machining error due totool deflection is serious even in the low cutting load, 2) by using the mechanistic simulation model with experimental coefficients, the machining error was predicted with maximum prediction error of 10% which was significantly reduced to the desired level by the path modification method.

• 한국정밀공학회지
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• 제16권7호
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• pp.203-209
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• 1999

In this paper, we present the methods to predict the milled surface shapes in profile milling process. In the cutting process, tools are deflected due to the cutting forces varying with the imposed depth of cut and feedrate. Thus, the final shapes of the milled surface, generated by the nominal tool trajectory, are different from the required profile. In order to predict the milled surface shapes, we present two methods based on: (1) the deflected tool profile and (2) the trace of contact point between the tool and the workpiece. In the first method, we make an assumption that the milled surface corresponds to the deflected tool profile. In another method, we make we make an assumption that the milled surface is generated by the trace of the contact point between the cutting edge of the tool and workpiece. We present the surface generation process by calculating the trajectory of the contact points on the workpiece. Several simulations and experiments are performed to verify the proposed milled surface prediction methods.

• 한국정밀공학회지
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• 제16권2호통권95호
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• pp.234-243
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• 1999

Using the geometric and the vector methods, three dimensional surface texture and roughness models in flat end milling are developed. In these models, rear cutting effect on surface generation is considered along with tool run-out and tool setting error including tool tilting and eccentricity between tool center and spindle rotational center. Rear cutting is the secondary cutting of the already machined surface by the trailing cutting edge. The effects of tool geometry and tool deflection on surface roughness are also considered. For representing the surface texture more practically, three dimentional surface topography parameters such as RMS deviaiton, skewness and kurtosis are introduced and used in expressing the surface texture characteristics. Under various cutting conditions, it is confirmed that the developed models predict the real surface profile precisely. These models could contribute to the cutter design and cutting condition selection for the reduction of machining and manual finishing time.

• 한국정밀공학회지
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• 제14권12호
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• pp.143-152
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• 1997

The deflection of an end mill is very important in machining process and cutting simulation because it affects directly workpiece accuracy, cutting force, and chattering. In this study, the deflection of the end mill was studied both experimentally and by using finite element analysis. And the moment of inertia of cross sections of the helical end mill is calculated for the determination of the relation between geometry of radial cross section and rigidity of the tools. Using the Bernoulli-Euler beam theory and the concept of equivalent diameter, a deflection model is established, which includes most influences from tool geomety parameters. It was found that helix angle attenuates the rigidity of the end mill by the finite element analysis. As a result, the equivalent diameter is determined by tooth number, inscribed diameter ratio, cross sectional geometry and helix angle. Because the relation betweem equivalent diameter and each factor is nonlinear, neural network is used to decide the equivalent diameter. Input patterns and desired outputs for the neural network are obtained by FEM analysis in several case of end milling operations.

• 한국소성가공학회:학술대회논문집
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• 한국소성가공학회 2001년도 춘계학술대회 논문집
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• pp.77-80
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• 2001

IC lead frame needs the precision shape for good efficiency. In the blanking process, there are many parameter effected the dimensional accuracy : lead width, blanking order, striper force, tool clearance etc. In this research, the4 undesirable defects appeared in the final blanking process. so we measured the deflection of lead according to the stripper force using $PAM-STAMP_{TM}$. In the result, the deflection was decreased by increasing the stripper force properly. and we changed the blanking order on the test model. In the blanking order, deflection is good from the outer line position blanking to center line position. so we can design the precision die without tryout by the prediction of the lead deflection.

• 한국생산제조학회지
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• 제8권2호
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• pp.100-107
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• 1999

End milling experiments are conducted to investigate characteristics of laser beam signals due to tool fracture. The laser beam signals are obtained with adapt focusing of tool. Tool states are identified wit h scanning electron microscopy and optical microscopy. It is demonstrated that the laser beam signals provide reliable informations about the cutting processes and tool states. Moreover, tool fracture can be detected successfully using coefficient of variation.